Auto-segmenting spherical projectile

ABSTRACT

Described are spherical projectiles such as used in birdshot, buckshot, or single ball spherical projectiles, including slugs, muzzle loading projectiles, or any close-to-bore diameter projectile, that is auto-segmenting or self-segmenting upon impact with a target. The projectile or shot disclosed herein retains its shape and structure during flight until impact with soft tissue, whereupon its individual sections separate or segment in a controllable manner, each portion of the projectile imparting or depositing a high amount energy to the tissue and target. The auto-segmenting spherical projectiles can be frangible or non-frangible. This disclosure also provides cartridges such as shotshells that are loaded with the projectiles described herein.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/329,418, filed Jan. 26, 2017, which is the 35 U.S.C. § 371 NationalStage application of International Patent Application No.PCT/US2015/042227, filed Jul. 25, 2015, which claims the benefit of U.S.Provisional Patent Application No. 62/030,545, filed Jul. 29, 2014, eachof which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

This disclosure relates to substantially spherical projectiles such asbirdshot, buckshot, or spherical slug projectiles and shotshellcartridges that are loaded with these spherical projectiles.

BACKGROUND

Projectiles for rifle and handgun ammunition (bullets) are oftendesigned with hollow or soft points or polymer-filled tips that allowthe projectile to expand in diameter upon impact with a soft tissuetarget. Specific design of the projectile allows control of itsexpansion such that the projectile penetrates sufficiently to hit vitalorgans, yet is still retained by and comes to rest within the target.Bullet retention is thought to allow all its kinetic energy to bedeposited within target, further enhancing its lethality. Even when thebullet does not come to rest within the target, if expansiondramatically slows the bullet, sufficient kinetic energy may bedeposited to the soft tissue to also increase lethality.

While such considerations have been important to the theory and practiceof bullet design, they are not readily applicable to designing sphericalprojectiles such as birdshot or buckshot. For example, bullets willconsistently impact the target with the nose or tip hitting the targetfirst, and bullet designs are based on this certainty. Sphericalprojectiles may hit the target without predictability in which leadingportion of the projectile will encounter the target first. Moreover whenmultiple shot projectiles are loaded into shotshells, they are typicallyor often loaded in random orientations. Therefore, applying conventionalbullet design considerations to improving spherical projectileperformance becomes an insurmountable problem.

What is needed is a design that allows generally spherical projectilessuch as shot to controllably expand in effective diameter when strikingsoft tissue. Such a design would be applicable regardless of the size ofthe shot, so that even large buckshot would still have a high likelihoodof being retained within the soft tissue target for energy deposit.

SUMMARY OF THE INVENTION

This disclosure describes generally a spherical projectile such as usedin birdshot, buckshot, or a single ball spherical projectile that isauto-segmenting or self-segmenting upon impact with a target. Theprojectile or shot disclosed herein retains its shape and structureduring loading, firing, and during flight until impact with soft tissue,whereupon its sections separate or segment in a controllable manner,each portion of the projectile imparting or depositing a high amount ofenergy to the tissue and target. This disclosure also providescartridges such as shotshells that are loaded with the projectiles orshot described herein.

According to an aspect, this disclosure provides an auto-segmentingspherical projectile, the projectile comprising:

-   -   a) at least 2 segments comprising a frangible material or a        non-frangible material;    -   b) at least one connecting element that contacts each segments        and separably connects the segments into a sphere.        Generally, the auto-segmenting spherical projectile can comprise        from 2 to 12. Also generally, the segments can be substantially        identically sized and/or substantially identically shaped. The        connecting element can be at the center of the spherical        projectile or off-center, and the segments can be        identically-shaped or non-identically-shaped. Further, the        auto-segmenting spherical projectile of this disclosure can be        or can comprise birdshot, buckshot, or spherical slugs.        Particularly useful are the auto-segmenting spherical        projectiles that comprise two perpendicular grooves defining the        segments, two parallel grooves defining the segments, or four        grooves in two perpendicular sets on opposite sides of the        sphere, defining the segments.

According to a further aspect, this disclosure provides a method ofmaking an auto-segmenting spherical projectile, the method comprising:

-   -   a) providing a powder comprising at least one metal;    -   b) providing a spherical powder metallurgy mold having one or        more internal ridges projecting toward the center of the sphere;        and    -   c) compacting the powder in the spherical mold to form an        auto-segmenting spherical projectile having one or more troughs        corresponding to the one or more internal ridges which define        segments of the projectile.        Generally, the spherical powder metallurgy mold can have two or        more internal ridges projecting toward the center of the sphere,        and the auto-segmenting spherical projectile can therefore have        two or more troughs corresponding to the two or more internal        ridges which define segments of the projectile.

The disclosed method of making an auto-segmenting spherical projectilecan be, for example, a cold compacting method or it can include at leastone heating step such as annealing or sintering. The auto-segmentingspherical projectile can be frangible or non-frangible. For example, theprojectile can comprise lead or be lead-containing, or it can belead-free. The process is particularly useful for making non-toxic,frangible or non-frangible projectiles such as auto-segmenting sphericalprojectiles that can comprises steel, bismuth, tungsten, tin, iron,copper, zinc, aluminum, nickel, chromium, molybdenum, cobalt, manganese,antimony, alloys thereof, or composites thereof.

A further aspect of this disclosure provides for shotshell cartridgesthat comprise at least one auto-segmenting spherical projectileaccording to the disclosure, or made according to the disclosed methods,or both. These and other aspects, embodiments, and features of thisdisclosure are discussed in detail below, and reference is made to thefigures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1D illustrate different views of an embodiment according tothis disclosure, namely, a hinged or “clamshell” auto-segmentingspherical projectile. FIGS. 1A, 1B, and 1C are different elevation viewsalong each of the x, y, and z axes, and FIG. 1D is a perspective view.

FIGS. 2A-2E illustrate different views of an embodiment according tothis disclosure, namely, a 2-slotted auto-segmenting sphericalprojectile. FIGS. 2A, 2B, and 2C are different elevation views alongeach of the x, y, and z axes, and FIG. 2D is a perspective view. In FIG.2C, the thickness of the connecting element is less than the distancefrom the circular edge of each hemispherical segment to the connectingelement.

FIG. 2E is an elevation view similar to that of FIG. 2C, in which thethickness of the connecting element is greater than the distance fromthe circular edge of each hemispherical segment to the connectingelement.

FIGS. 3A-3D illustrate different views of an embodiment according tothis disclosure, namely, a 4-slotted auto-segmenting sphericalprojectile. FIGS. 3A, 3B, and 3C are different elevation views alongeach of the x, y, and z axes, and FIG. 3D is a perspective view.

FIG. 4 illustrates a perspective view of an embodiment according to thisdisclosure, namely, a 4-slotted auto-segmenting spherical projectile,with the center connector illustrated.

FIG. 5 illustrates an elevation view of an embodiment according to thisdisclosure, namely, a parallel two-slotted auto-segmenting sphericalprojectile, with the two slots oriented in a parallel fashion.Two-slotted auto-segmenting spherical projectiles of this type can bemade by a compacted powder (powder metallurgy) method.

FIG. 6 illustrates an elevation view of an embodiment according to thisdisclosure, namely, a perpendicular two-slotted auto-segmentingspherical projectile, with the two opposing slots oriented in aperpendicular fashion. Two-slotted auto-segmenting spherical projectilesof this type can be made by a compacted powder (powder metallurgy)method.

DETAILED DESCRIPTION OF THE INVENTION

This disclosure describes generally a spherical projectile such as usedin birdshot, buckshot, or a single ball spherical projectile, includinga slug or muzzle loading projectile or close-to-bore diameterprojectile, that is auto-segmenting or self-segmenting upon impact witha target. The projectile or shot disclosed herein retains its shape andstructure during loading, firing, and during flight until impact withsoft tissue, whereupon its sections separate or segment in acontrollable manner, each portion of the projectile imparting ordepositing a high amount energy to the tissue and target. It has beenunexpectedly found that projectiles can be fabricated thatauto-segmenting in a controlled and predictable fashion upon impact witha desired target, regardless of the projectile's orientation withrespect to the target.

According to one aspect, the auto-segmenting projectiles of thisdisclosure can comprise non-frangible segments, such that theyauto-segment upon impacting a soft tissue or other target, but otherwisedo not generally break apart. In a further aspect, the auto-segmentingprojectiles can comprise frangible segments, such they auto-segment uponimpacting soft tissue, but break apart into countless irregular-shapedparticles, typically resembling dust, upon striking an unyielding, hardtarget. The latter provides a method of increasing the lethality withrespect to soft tissue and also increasing the safety with respect toreducing or substantially eliminating over-penetration of the sphericalprojectile. Further, the projectiles, shotshells, and methods of thisdisclosure are applicable to any size spherical projectile.

The term “spherical” projectile is understood by the skilled person inthe art to mean “substantially spherical,” and is used primarily todistinguish the disclosed projectiles from bullets designed for riflecartridges. That is, it is recognized that the disclosed projectiles aregenerally useful in shotshell loadings and may include surface featuresthat impart slight out-of-round properties to the projectile. Thesefeatures may arise as an artifact of the manufacturing method (such asin a powder metallurgy or “compacted powder” method), an intentionallyimparted structural feature (such as a cutting edge feature),unintentional structural feature (such as a burr), or the like. All ofthese features and departures from perfect spheres are recognized by theskilled person to be elements and aspects that may occur in projectilesthat are generally regarded as “spherical” and are useful in shotshellloadings.

The present design does not require any particular portion of theauto-segmenting spherical projectile or shot to encounter the targetfirst, that is, no specific leading edge of the spherical projectile isrequired to hit the target first to ensure auto-segmentation andseparation of the sections of the projectile. As a result, the disclosedprojectiles are particularly useful for birdshot, buckshot, single ballprojectiles, or any similar spherical projectile in which loading andfiring from a shotshell results in random orientations of theprojectiles at the target. This disclosure also provides cartridges suchas shotshells that are loaded with the spherical auto-segmentingprojectiles or shot described herein.

Aspects of the present disclosure are particularly illustrated in thefigures, and FIGS. 1-6 present a good comparison and illustration of howthese aspects of the disclosed projectiles can vary. Generally, thespace or gap between the individual segments in the figures may beexaggerated to more clearly illustrate the representative shapes andstructures. The various illustrated aspects of the projectiles can varyaccording to the particular need. For example, the material itself canvary in composition, density, hardness and the like. The overall segmentitself and the connection(s) between segments can vary in structure,size, and shape, to achieve a projectile specific to the desiredvelocity, the characteristics of the target, the desired ease or rate ofopening and separating of the segments, and other particular designneeds. In addition, the number, relative orientation, depth, and shapeof the cuts (that is, troughs or channels) in a projectile such asillustrated in FIG. 5 and FIG. 6 can vary and are found to produceauto-segmenting under somewhat different conditions such as velocity andtarget density.

In one aspect, the segment structure in the present projectiles isdifferent than that of previous projectiles that are characterized bybeing “scored” to form lines of weakness, along which the projectilewill separate into petals and/or break apart upon impact. Such scoringis found, for example, in a jacketed bullet, and the scoring can be onlyin the jacket itself or in the jacket and into the underlying bullet aswell. The present projectiles do not include merely weakened parts, butrather substantially separated portions that are joined with a connectorof a specific shape, size, composition, and structure. In this aspect,the thickness of the connector can be less than or equal to the depth ofthe cut in the substantially spherical projectile. In some aspects, thethickness of the connector can be greater than or equal to the depth ofthe cut in the substantially spherical projectile. However, in eithercase, the projectile is designed to separate when striking a desiredtarget.

Thus, while not intending to be bound by theory, it has been found thatto achieve the auto-segmentation feature of the present design does notrequire any particular portion of the spherical shot to encounter thetarget first, and it has been found that segmented (not scored) portionsof a spherical projectile work well. The planes and/or lines of“separation” in the disclosed segmented projectile contrast to the merelines of “weakness” in a scored projectile. The weakened (scored)structure requires a large amount of energy to split the projectilealong the scored lines, such energy generally being available only inrifle or pistol bullets. In contrast, because the spherical projectilesof this disclosure are already largely separated, being connected atonly a portion of the contiguous area, separation is readily achieved inlower velocity projectiles as desired.

The disclosed segmented portions are capable of withstanding the rigorsof manufacturing, loading, and firing and remain connected, yet can beprogrammed for disruption by impact with a soft tissue target. While notbound by theory, it is thought that disruption and breaking apart of theauto-segmenting projectile can occur by the hydrostatic/hydraulicpressure created by impact with a soft tissue target and/or by shearingof the connector upon impact and the uneven pressure resulting fromimpact upon striking soft tissue or hard surfaces, regardless oforientation. By eliminating the need to have the projectile oriented ina particular direction upon striking the target, the present design canbe used as shot in shotshells or for any spherical projectile. Thisdesign greatly expands the utility of the spherical projectiles, becausethey can be fabricated with selected materials, varying connectorthickness, and the like, to initiate disruption and breaking apart whenlaunched at very low velocities, medium velocities, or only at highvelocities, depending upon the need.

FIGS. 1A-1D illustrate different views of one aspect and embodimentaccording to the disclosure, namely, a hinged or “clamshell” typeauto-segmenting spherical projectile. This hinged or “clamshell”auto-segmenting spherical projectile shown in FIGS. 1A-1D comprises twohemispherical sections connected by a post, hinge, or more generally,connector or connecting element, that is at or near an edge of eachhemisphere's circular face. In this figure, the space or gap between theindividual segments is exaggerated for clarity. In some embodiments, thecut between segments can be less than, equal to, or more than halfwaythrough the projectile diameter. The deep or more than halfway throughthe projectile diameter is shown in FIGS. 1A-1D. The flat, internalsurfaces or faces of the segments arising from this clamshell structurecan be touching each other in some embodiments.

FIGS. 2A-2E illustrate different views of an embodiment according tothis disclosure referred to as a 2-slotted auto-segmenting sphericalprojectile, or “2-slot” projectile. The 2-slot auto-segmenting sphericalprojectile also comprises a projectile having two hemispherical sectionsconnected by a connecting element that is at or near the center of eachhemisphere's circular face. The post or connector element can vary inthickness to afford different levels of stability to the sphericalprojectile before segmentation initiates upon striking a target.

FIGS. 3A-3D and FIG. 4 illustrate different views of an embodimentaccording to this disclosure referred to as a 4-slotted auto-segmentingspherical projectile, or “4-slot” projectile. The 4-slot auto-segmentingspherical projectile comprises a projectile having four quadrasphericalsections connected by a connecting element or moiety that is at or nearthe center of each quadraspherical section's right angle edge at theinner portion of the overall sphere. Another aspect of a 4-slot designis illustrated in FIG. 4, in which a substantially spherical connectoris illustrated. The post or connector element can vary in thickness toafford different levels of stability to the spherical projectile beforesegmentation initiates upon striking a target.

FIG. 5 illustrates another aspect of this disclosure, namely, atwo-slotted auto-segmenting spherical projectile in which the two slotsare oriented in a parallel fashion. A powder metallurgy method workswell to fabricate two-slotted auto-segmenting spherical projectiles ofthis type. The depth of the cut between segments can be more thanhalfway through the projectile diameter as shown in this figure.Alternatively, the depth of the cut between segments can be less than orroughly equal to the projectile diameter if desired. It is noted thatthe angle of the cut shown in the view of FIG. 5 can vary from verysmall (for example, less than)5° to fairly large (for example, up toabout)45°, and any angle between. That is, the angle of the cut can beabout 5°, about 10°, about 15°, about 20°, about 25°, about 30°, about35°, about 40°, or about 45°. The circular belt around the circumferenceof the projectile that is shown is a typical feature that can arise inthe pressed metal powder method. This compacted powdered metal method isparticularly useful for making non-toxic and/or frangible pellets.

FIG. 6 illustrates another aspect of the disclosure, namely, atwo-slotted auto-segmenting spherical projectile in which the two slotsare oriented in a perpendicular fashion, that is, in a “criss-cross”fashion. It is noted that in this two-slotted configuration, therelative orientation of the two slots can be at any angle betweenparallel (as in FIG. 5) and perpendicular (as in FIG. 6). The powdermetallurgy method works well to fabricate such spherical projectiles.Again, depth of the cut between segments can be more than halfwaythrough the projectile diameter as shown in this figure, or can be lessthan or roughly equal to the projectile diameter if desired. The angleof the cut shown in the view of FIG. 6 also can vary from very small(for example, less than)5° to fairly large (for example, up toabout)45°, and any angle between. That is, the angle of the cut can beabout 5°, about 10°, about 15°, about 20°, about 25°, about 30°, about35°, about 40°, or about 45°.

According to a further aspect, either of the embodiments of FIG. 5 orFIG. 6 can represent the starting point for further embodiments, inwhich a further cut (trough) is imparted perpendicular to and acrosseach of the cuts (troughs) shown FIG. 5 or FIG. 6. In this fashion, theauto-segmenting spherical projectile can be fabricated with eight (8)segments. By describing the projectile as formed with “cuts,” it is notintended to limit the method of fabrication to one in which actualslices or cuts are made into an initially spherical starting object.Rather, this method of describing the “cuts” in the projectile is usedto explain the overall structure of the projectile, regardless of howthe cuts and resulting connector are fabricated. For example, thepressed or compacted powder method works well to compact powderedmaterials such as metals into an object of the desired shape such asshown, and this method is useful for making non-toxic and/or frangiblepellets. In this method, fabricating spheres with any number andorientation of cuts can be readily understood and carried out by theperson of skill in the art, and the process can be cost effective andefficient. As described, a circular belt around the circumference of theprojectile that is shown in FIG. 5 and FIG. 6 is a typical feature ofpressed metal powder method, and as used herein, such projectiles aredescribed as spherical. If desired, such pellets can be tumbled orotherwise finished to smooth the outer curvature.

According to a further aspect, the auto-segmenting spherical projectilescan be made by various powder metallurgy processes. For example, powdermetallurgy processes include but are not limited to cold compactionprocesses, press and sinter (both solid-state and liquid-phase)processes, and metal injection molding processes. In addition, any ofthese powder metallurgy processes may optionally be followed bysubsequent working of the article, such as by forging, extrusion,swaging, grinding, annealing, and/or sintering or other heat treatment.Moreover, composite materials can be made in this fashion and caninclude composites containing ceramics, polymers, and glasses, as wellas metals. If desired, prior to placing the composition used to preparethe spherical projectile into a die or other mold, the die or mold maybe lubricated to facilitate easier removal of the compacted article.

The process of fabricating the projectiles of this disclosure caninclude the formation of an intermediate structure, which can bereshaped if desired or further processed by a subsequent treatment. Forexample, the fabrication process can be carried out with or withoutheating the intermediate structure. Additionally or alternatively, theintermediate structure may be heated, including heating to the point ofannealing and/or sintering. Although typically occurring after acompression step, one or more types of heating of an intermediatestructure and/or article may occur at one or more stages during theformation process, including before, during and/or after the compressionstep. It also should be understood that heating is not required in someembodiments, and that articles may be produced according to the presentinvention without requiring the composition of matter to be heated.Typically, frangible projectiles are not sintered, but they may (or maynot) be heated or annealed. Sintering may be either solid-phasesintering, in which the article is heated to near the melting point ofthe lowest melting component, or liquid-phase sintering, in which thearticle is heated to or above the melting point of the lowest meltingcomponent.

In one aspect, the auto-segmenting projectiles of this disclosure cancomprise either frangible or non-frangible materials used to fabricatethe projectile. A distinction is made between auto-segmenting behaviorversus frangible behavior. A projectile made of non-frangible materialsmay auto-segment into the number of segments comprising the projectile,upon impacting a soft tissue or most other targets, but otherwise theindividual segments may not generally break apart. A projectile made offrangible materials may auto-segment into the number of segmentscomprising the projectile upon impacting soft tissue, but otherwisebreak apart into countless irregular-shaped particles resembling dustupon striking a hard target, thereby preventing over-penetration. Forexample, a steel-copper composite projectile according to thisdisclosure can be fabricated into a frangible structure, which willbreak apart upon impacting soft tissue, but otherwise shatter into apowder when impacting a hard surface.

Applications of such projectiles made of frangible materials includebuckshot for law enforcement, military, or self-defense use, whereauto-segmenting technology combined with frangibility would lower therisk of richochet and/or collateral damage (for example, fromover-penetration). However, when impacting tissue, the frangibility ofthe projectile does not manifest itself but auto-segmenting does.Therefore, such projectiles can penetrate clothing and tissue andauto-segment, thereby providing improved terminal performance of thebuckshot. Such projectiles can be fabricated using non-toxic metals andmaterials, if desired. In one aspect, the frangible material can have adensity lower than lead, and still afford excellent stopping power dueto depositing its kinetic energy within target upon auto-segmenting. Thecompacted powdered metal method of making spherical projectiles(pellets) works well for these projectiles, particularly for fabricatingnon-toxic and/or frangible pellets.

Depending upon several factors, the auto-segmenting process can includea complete separation of the segments from every other segment (or mostof the other segments) in the projectile, or alternatively, can includean opening up of the projectile, for example, in the clamshellprojectile of FIGS. 1A-1D, without breaking the projectile completelyapart at the connector or hinge. Such behavior may prove useful in, forexample, limiting penetration in soft tissue when such behavior isdesired. Projectile features such as the material used to fabricate theprojectile, the thickness or shape of the connector (such as in FIGS.1A-1D and FIGS. 2A-2E embodiments) and/or the depth of the cuts (such asin the FIG. 5 and FIG. 6 embodiments) can be adjusted to tailor theextent of separation of the segments. For example, a copper projectilefabricated with a clamshell structure such as in FIGS. 1A-1D, but with alarge hinge, may merely open but not break apart the clamshell uponimpacting soft tissue. By describing the connector as “separablyconnecting” the individual segments of the auto-segmenting sphere, it isintended to include the auto-segmenting process in which completeseparation of the segments from the every other segment, partialseparation of the segments from some other segments, or no separationbut an “opening up” and expansion of the size of the projectile occur.

The auto-segmenting projectiles can be fabricated with a small number ofsimilarly-sized and similarly-shaped sections, for example, 2, 3, 4, 5,6, 7, 8, 9, 10, 11, 12, or more portions, and generally break into thesenumber of segments upon impact. Typically, the auto-segmentingprojectiles can be fabricated with, and generally separate into, 2, 3,4, 5, 6, 7, or 8 portions. More typically, the auto-segmentingprojectiles can be fabricated with, and generally separate into, 2, 4,or 8 portions, each usually but not necessarily identical in size andshape. In contrast, a conventional frangible projectile is designed todisintegrate into tiny particles upon impact, specifically to minimizethe particles' penetration. Controlled penetration is desired andachieved for the auto-segmenting projectiles.

According to one aspect, the segments of the spherical projectileaccording to the disclosure can be identically-shaped, such as presentedin the figures. However, identically-shaped projectiles are notrequired, and some segments of the spherical projectile according to thedisclosure can be non-identically-shaped. For example,non-identically-shaped segments of the spherical projectile could beformed and connected using a connecting element according to thisdisclosure. A further aspect, the segments can be assembled into asphere in a symmetric fashion. In another example,non-identically-shaped segments of the spherical projectile could becreated by forming two or more identical segments, followed by furtherdividing each segment into an unequal shaped or sized sub-segment.Again, generally these non-identically-shaped segments are assembledinto a sphere in a symmetric fashion.

As a review of the figures illustrates, there are several variables inthe design of the projectiles that can be adjusted to attain the desiredlevel of ease of separation and performance with each of the particularvariables providing a high level of control in building in the desiredperformance to the projectile. By way of example, the size, shape,diameter (thickness), number, width, and composition of the connector(s)(sometimes referred to as “segment-connector” or “connecting element” orsimilar terms) that separably connects the individual segments can beadjusted to allow rapid or slower separation of the segments, which canalter the depth of penetration at which complete separation occurs.Thus, the connector element size, shape, diameter (thickness), number,width, and composition are design adjustable aspects that affect theability of the spherical projectile to hold together and maintain itsspherical integrity during the shotshell loading process, duringcartridge firing, during flight, and until impact occurs. This abilityto maintain its spherical integrity until impact is referred to as thesegments being “separably connected”. Generally, the overall sphericalshape is retained when the segments are connected, and the connectorfeatures typically will not alter this aspect substantially.

In addition, these size, shape, diameter, and width features of theconnecting element also allow adjusting the space or clearance betweenadjacent segments as needed. Some embodiments include a connect that ispost-shaped, but the use of the term “post” to generally describe theconnector does not necessarily limit the shape of the connector to apost- or column-shape unless the context requires otherwise. Generally,the connector or “post” will be shaped according to the fabricationmethod. When the segments are fabricated by cutting a sphere comprisinga soft metal versus a powder metallurgy method using a spherical moldhaving ridges to impart cuts or grooves in the sphere, the shape of theconnector may be substantially different.

Further, the exact location of the connecting element that separablyconnects the individual segments can be adjusted. Again, this aspectallows for controlling the rapid or slower separation of the segmentsand allows segments to be separated in series (in sequence) orsimultaneously, which can alter the performance and depth at which thefinal and complete separation occurs. The figures generally demonstrate“end members” of a continuum of connecting element locations. That is,the connector can be situated at or near an edge of each section, at ornear the center (or center of an edge) of each section, or anywhere inbetween these two positions. Adjusting connector location allowsfine-tuning of performance. Because more than one connector is anenvisioned aspect, adjusting connector location and number furtheraffords an ability to fine-tune performance.

The segments themselves are not required to be perfect hemispheres orquadraspheres and the like as illustrated in the figures. For example,and while not intending to be bound by theory, small to medium sizedchamfers or bevels can be added along an edge where the segments meet.Such chamfers are thought to better allow the hydrostatic pressure ofthe contacting soft tissue or fluid to enter the space between thesegments and initiate the auto-segmentation process. Any size, shape,number, and spacing of chamfers can be employed, each of which permitscareful tailoring of auto-segmentation performance Other features suchas dimples or small holes envisioned along the “lines of separation” toallow better collection and focusing of hydrostatic pressure, to allowthe segments to be wedged apart upon contact. For all these features,the number, depth, width, and overall size can be adjusted for thedesired separating effect.

The composition of the connecting element that separably connects theindividual segments also can be adjusted to allow control over theseparation of the segments, and to provide additional embodiments thatare more easily fabricated than others. The composition of the connectorcan be the same metal as the projectile, a different metal, a compositematerial, a polymeric material, a thermoplastic material, a thermosetmaterial, an adhesive material, and the like. Moreover, a singleshotshell load could contain projectiles of the same or different sizesthat can be connected with connecting elements having differentcompositions.

The material from which the projectile itself is fabricated can varyconsiderably. For example, in accordance with another aspect, theauto-segmenting projectile can comprise lead or be lead-containing, orthe projectile can be lead-free. Alternatively, the entire projectilecan be non-metallic. For example, in some aspects and embodiments, theprojectile can comprise lead, steel, bismuth, tungsten, tin, iron,copper, zinc, aluminum, nickel, chromium, molybdenum, cobalt, manganese,antimony, alloys thereof, composites thereof, or any combinationsthereof.

The auto-segmenting spherical projectiles can be any size. For example,the spherical projectiles can be sized according to birdshot, buckshot,spherical slugs, or any single ball spherical projectile such as a slugor muzzle loading projectile or close-to-bore diameter projectile. Theauto-segmenting spherical projectiles can be sized, for example,according to lead or steel shot sizes. Table 1 presented belowreproduces standard shot sizes as a non-limiting illustration of thisaspect, and any of the sizes shown and sizes not presented in this tablecan be prepared as described in this disclosure. Thus, even singlespherical slugs can be used according to this disclosure that are sizedfor the particular firearm, for example a muzzle loaded firearm.

TABLE 1 Standard Shot Sizes Lead shot sizes: 12 9 8½ 8 7½ 6 5 4 2 BBPellet diameter .05 .080 .085 .090 .095 .110 .120 .130 .150 .180(inches) (mm) 1.27 2.30 2.16 2.29 2.41 2.79 3.05 3.30 3.81 4.57 Buckshotsizes: No. 4 No. 3 No. 2 No. 1 No. 0 No. 00 No. 000 Pellet diameter .24.25 .27 .30 .32 .33 .36 (inches) (mm) 6.10 6.35 6.86 7.62 8.13 8.38 9.14Steel shot sizes: 6 5 4 3 2 1 Air Rifle BB BBB T F Pellet diameter .11.12 .13 .14 .15 .16 .177 .18 .19 .20 .22 (in.) (mm) 2.79 3.05 3.30 3.563.81 4.06 4.49 4.57 4.83 5.08 5.59 Note: the size of shot, whether leador steel, is based on American Standard shot sizes. Thus, a steel No. 4pellet and a lead No. 4 pellet are both .13 inches (3.3 mm) in diameter.

The spherical projectiles of this disclosure can be fabricated by anymethod known in the art. In an aspect, for example, the projectiles canbe fabricated from a solid spherical ball by cutting into but notthrough the solid spherical ball according to the desired segmentpattern to create the segments and create the post or connecting elementthat connects the segments. This method of cutting around the post orconnector can be applied to situate the connector at any desiredlocation and having any desires shape. In other aspects, the projectilesof this disclosure can be fabricated from pre-formed segments that willform the solid spherical ball by introducing a connecting element madeof the same metal as the projectile segments, a different metal, acomposite material, a polymeric material, a thermoplastic material, andthe like, for example by softening these materials so that they can besituated or placed in the desired location and made to contact eachsegment. Alternatively, an adhesive material can be used to create thepost or connecting element, either alone or in combination with any ofthe aforementioned materials. In other aspects the post or connectingelement can be prepared in situ using a thermoset material to contactthe segments or by heating and softening the segments themselves andcontacting them to form the connecting element at the contact point orcontact area. Other aspects provide for separately creating segmentshaving any desired chamfers or other features as disclosed anddepositing softened or liquefied metal at the desired connector locationon one segment, followed by contacting the softened connector metal bythe other segment or segments.

As described in this disclosure, the various projectile aspects andfeatures allow for tailoring the shot for the rate of opening, thepenetration projectile, the number of segments desired, and generallyadjusting the shot for its intended target, whether for deer orwaterfowl hunting or for military, law enforcement, or personal defenseuse.

Again while not intending to be bound by theory, it is observed that thedisclosed projectiles are capable of consuming a minimal amount ofenergy to cause segmenting upon impart. This feature may be particularlyapplicable to lower density materials, which do not have sufficientterminal velocity (retained speed) or energy upon impact to beparticularly effective. Using the auto-segmenting design in sphericalprojectiles made of lower density materials such as steel provides amuch greater energy deposit into the target than any conventionaldesign. While not theory-bound, it is thought that the present designgreatly improves the transmission of “dumping” of energy from theprojectile to the living tissue. Once segmented, multiple wound channelsare generated, and a greatly enlarged hydrostatic pressure wave zone isgenerated when the multiple segments diverge in the tissue. Moreover,segmentation or “auto-segmentation” is achieved regardless of theorientation of the projectile at impact. Therefore, it is thought thatprojectiles of low density generally that are typically required forwaterfowl loads may benefit greatly from the present design by havingmuch greater killing power than convention low density projectiles,because of the low energy requirement to induce segmenting but thegreater energy deposit from multiple segments.

It is also thought that the chamfered edges when included in theprojectiles function as pressure-collecting or pressure-concentratingfeatures. That is, the recessed or dimpled structure along the edges asdisclosed herein can help ensure that controlled opening of thesegmented projectile occurs regardless of the orientation of thesegmented projectile and therefore regardless of which leading edge ofthe spherical projectile strikes the target first.

This disclosure also provides for shotshells comprising any of theprojectiles disclosed herein. Supporting aspects of this disclosure arefound, for example, in the following publications, each of which isincorporated herein by reference in its entirety: Thomas J. Griffin,ed., Shotshell Reloading Handbook, 5^(th) ed., Lyman Publications, LymanProducts Corporation, Middletown, Conn. (2007); Don Zutz, Hodgdon PowderCompany Shotshell Data Manual, 1^(st) ed., Hodgden Power Company,Shawnee Mission, Kans. (1996); Bob Brister, Shotgunning: The Art and theScience, Winchester Press, New Win Publishing, Inc., Clinton, N.J.(1976); and U.S. Patent Application Publication No. 2011/0017090. Thus,shotshell cartridges according to this disclosure can employ standardshotshell components and loading methods for their construction. By wayof example, the shotshell cases or hulls, primers, propellant or powder,shot or other projectiles such as slugs, gas seals, and the like, haveall been described in abundant detail in these cited references.

Throughout this specification, various publications may be referenced.The disclosures of these publications are hereby incorporated byreference in pertinent part, in order to more fully describe the stateof the art to which the disclosed subject matter pertains. Thereferences disclosed are also individually and specifically incorporatedby reference herein for the material contained in them that is discussedin the sentence in which the reference is relied upon. To the extentthat any definition or usage provided by any document incorporatedherein by reference conflicts with the definition or usage providedherein, the definition or usage provided herein controls.

As used in the specification and the appended claims, the singular forms“a,” “an,” and “the” include plural referents, unless the contextclearly dictates otherwise. Thus, for example, reference to “aprojectile” includes a single projectile such as a slug, as well as anycombination of more than one projectile, such as multiple pellets ofshot of any size or combination of sizes. Also for example, reference to“a projectile” includes a single shot pellet having the featuresdisclosed herein, or multiple shot pellets according to this disclosure,such as would be found, for example, in a loaded shotshell incorporatingsuch pellets or projectiles.

Throughout the specification and claims, the word “comprise” andvariations of the word, such as “comprising” and “comprises,” means“including but not limited to,” and is not intended to exclude, forexample, other additives, components, elements, or steps. Whilecompositions and methods are described in terms of “comprising” variouscomponents or steps, the compositions and methods can also “consistessentially of or “consist of' the various components or steps.

“Optional” or “optionally” means that the subsequently describedelement, component, step, or circumstance can or cannot occur, and thatthe description includes instances where the element, component, step,or circumstance occurs and instances where it does not.

Unless indicated otherwise, when a range of any type is disclosed orclaimed, for example a range of the particle sizes, percentages,temperatures, and the like, it is intended to disclose or claimindividually each possible number that such a range could reasonablyencompass, including any sub-ranges or combinations of sub-rangesencompassed therein. When describing a range of measurements such assizes or weight percentages, every possible number that such a rangecould reasonably encompass can, for example, refer to values within therange with one significant figure more than is present in the end pointsof a range, or refer to values within the range with the same number ofsignificant figures as the end point with the most significant figures,as the context indicates or permits. For example, when describing arange of percentage numbers such as from 85% to 95%, it is understoodthat this disclosure is intended to encompass each of 85%, 86%, 87%,88%, 89%, 90%, 91%, 92%, 93%, 94%, and 95%, as well as any ranges,sub-ranges, and combinations of sub-ranges encompassed therein.Applicants' intent is that these two methods of describing the range areinterchangeable. Accordingly, Applicants reserve the right to provisoout or exclude any individual members of any such group, including anysub-ranges or combinations of sub-ranges within the group, if for anyreason Applicants choose to claim less than the full measure of thedisclosure, for example, to account for a reference that Applicants areunaware of at the time of the filing of the application.

Values or ranges may be expressed herein as “about”, from “about” oneparticular value, and/or to “about” another particular value. When suchvalues or ranges are expressed, other embodiments disclosed include thespecific value recited, from the one particular value, and/or to theother particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another embodiment. It will be furtherunderstood that there are a number of values disclosed herein, and thateach value is also herein disclosed as “about” that particular value inaddition to the value itself.

In any application before the United States Patent and Trademark Office,the

Abstract of this application is provided for the purpose of satisfyingthe requirements of 37 C.F.R. § 1.72 and the purpose stated in 37 C.F.R.§ 1.72(b) “to enable the United States Patent and Trademark Office andthe public generally to determine quickly from a cursory inspection thenature and gist of the technical disclosure.” Therefore, the Abstract ofthis application is not intended to be used to construe the scope of theclaims or to limit the scope of the subject matter that is disclosedherein. Moreover, any headings that are employed herein are also notintended to be used to construe the scope of the claims or to limit thescope of the subject matter that is disclosed herein. Any use of thepast tense to describe an example otherwise indicated as constructive orprophetic is not intended to reflect that the constructive or propheticexample has actually been carried out.

Those skilled in the art will readily appreciate that many modificationsare possible in the exemplary embodiments disclosed herein withoutmaterially departing from the novel teachings and advantages accordingto this disclosure. Accordingly, all such modifications and equivalentsare intended to be included within the scope of this disclosure asdefined in the following claims. Therefore, it is to be understood thatresort can be had to various other aspects, embodiments, modifications,and equivalents thereof which, after reading the description herein, maysuggest themselves to one of ordinary skill in the art without departingfrom the spirit of the present disclosure or the scope of the appendedclaims.

We claim:
 1. A cartridge comprising: a) a cartridge case having a foreend and an aft end, the cartridge case comprising a primer situated atthe aft end; b) a propellant adjacent the primer; and c) an obturatingcomponent adjacent the propellant; and d) a shot load adjacent theobturating component, the shot load comprising one or more sphericalprojectiles, each spherical projectile comprising: 1) two solidhemispherical segments, each comprising a circular face oriented towardthe center of the spherical projectile, a circular edge, and anuninterrupted hemispherical surface; and 2) a connecting elementattached to each circular face off-center towards the circular edge andhaving a thickness, wherein the two hemispherical segments and theconnecting element are monolithic, and wherein the thickness of theconnecting element is less than the diameter of each circular face.
 2. Acartridge according to claim 1, wherein the connecting element isattached to each circular face at each circular edge, thereby forming ahinge connecting the two hemispherical segments.
 3. A cartridgeaccording to claim 1, wherein the thickness of the connecting element isless than half the diameter of the hemispherical segment.
 4. A cartridgeaccording to claim 1, wherein the one or more spherical projectilescomprises lead, steel, bismuth, tungsten, tin, iron, copper, zinc,aluminum, nickel, chromium, molybdenum, cobalt, manganese, antimony,alloys thereof, or composites thereof.
 5. A cartridge according to claim1, wherein the one or more spherical projectiles is lead-free.
 6. Acartridge according to claim 1, wherein the one or more sphericalprojectiles comprises a frangible material.
 7. A cartridge according toclaim 1, wherein the one or more spherical projectiles are selected frombirdshot, buckshot, or a single ball spherical projectile.
 8. Acartridge according to claim 1, wherein the circular edge of the one ormore spherical projectiles is chamfered.
 9. A cartridge according toclaim 1, wherein the shot load further comprises a buffer.
 10. Acartridge according to claim 1, wherein the obturating component is apre-formed component comprising a gas seal.
 11. A cartridge according toclaim 1, wherein the obturating component is a pre-formed componentcomprising a gas seal section and a shot cup section containing the shotload.
 12. A cartridge according to claim 1, wherein the obturatingcomponent is a pre-formed component comprising a gas seal section, ashot cup section containing the shot load, and a collapsible sectionbetween the gas seal section and the shot cup section.
 13. A cartridgeaccording to claim 1, wherein the obturating component is an obturatingmedium comprising a particulate polymeric material.
 14. A cartridgeaccording to claim 13, wherein the obturating medium comprises apolyethylene, a polypropylene, or a combination thereof.
 15. A cartridgeaccording to claim 1, wherein the fore end of the cartridge case iscrimped.
 16. A cartridge according to claim 1, wherein the connectingelement comprises: a) a flat side oriented toward the center of thespherical projectile; and b) a arcuate side oriented along the circularedge of the spherical projectile.
 17. A cartridge comprising: a) acartridge case having a fore end and an aft end, the cartridge casecomprising a primer situated at the aft end; b) a propellant adjacentthe primer; and c) an obturating component adjacent the propellant, theobturating component comprises a pre-formed gas seal or an obturatingmedium; and d) a shot load adjacent the obturating component, the shotload comprising one or more spherical projectiles, each sphericalprojectile comprising: 1) two solid hemispherical segments, eachcomprising a circular face oriented toward the center of the sphericalprojectile, a circular edge, and an uninterrupted hemispherical surface;and 2) a connecting element attached to each circular face at thecircular edge thereby forming a hinge connecting the two hemisphericalsegments, and having a thickness, wherein the two hemispherical segmentsand the connecting element are monolithic, and wherein the thickness ofthe connecting element is less than half the diameter of thehemispherical segment.
 18. A method of loading a cartridge comprising:a) providing or obtaining a cartridge case having a fore end and an aftend, the cartridge case comprising a primer situated at the aft end; b)sequentially loading into the cartridge case [1] a propellant adjacentthe primer, [2] an obturating component comprising a pre-formed gas sealor an obturating medium, and [3] a shot load, wherein the shot loadcomprising one or more spherical projectiles, each spherical projectilecomprising: 1) two solid hemispherical segments, each comprising acircular face oriented toward the center of the spherical projectile, acircular edge, and an uninterrupted hemispherical surface; and 2) anoff-center connecting element attached to each circular face and havinga thickness, wherein the two hemispherical segments and the connectingelement are monolithic, and wherein the thickness of the connectingelement is less than the diameter of each circular face.